Cushioned overlay with durable, liquid impermeable, slip-resistant outer layer

ABSTRACT

A cushioned overlay includes a foam core containing a dampening liquid atop an liquid impermeable substrate and covered with an outer liquid impermeable, durable, slip-resistant layer. The dampening liquid may be water, oil, glycerine or other compatible liquid. The foam may be a memory foam. The outer layer may be a rubber-based material vinyl, such as a marine or faux leather vinyl.

FIELD OF THE INVENTION

This invention generally relates to cushioned surfaces, and more particularly, to a cushioned overlay comprised of a foam core saturated with a liquid and disposed atop an liquid impermeable substrate and covered with an outer liquid impermeable, durable, slip-resistant layer.

BACKGROUND

Various living area and workplace surfaces are hard, uncomfortable, slippery when wet, and conducive to serious injury in the event of a slip and fall. By way of example and not limitation, conventional bathtubs, shower stalls, tile and the like feature hard unyielding surfaces that are not well suited for comfort. Concomitantly, these hard surfaces pose serious risks of injury due to their tendency to become slippery when wet greasy and/or soapy. Consequently, bathtub, shower and flooring falls account for a high percentage of minor and serious injuries, due to the hard and slippery surfaces.

Other floor and wall surfaces in homes and workplaces suffer similar shortcomings. For example, bathroom and kitchen floors often become slippery and pose serious risks of slip and fall accidents. Other home, industrial and workplace floor surfaces and mats are hard and unyielding, providing little pressure relief and dampening effect, and causing discomfort for workers who must stand on the surfaces for extended periods of time. Conventional cushioned mats, pads and footwear inserts lose their resiliency after extended use.

While anti-slip coatings, mats and the like have been devised to reduce the risk of slip and fall accidents, such devices also have shortcomings. They are typically not well-cushioned, soft and resilient. Thus, for example, they provide an uncomfortable surface for sitting, standing and/or lying.

Accordingly, a need exists for a cushioned surface, and more particularly, for a cushioned surface with a resilient core covered with an outer liquid impermeable, durable, slip-resistant layer. The outer layer should preferably also be easy to clean, fire retardant, durable, abrasion and stain resistant, and aesthetically pleasing. The invention is directed to overcoming one or more of the problems and solving one or more of the needs as set forth above.

SUMMARY OF THE INVENTION

In one aspect of an exemplary embodiment of the invention, a cushioned structure is provided comprising a durable, liquid impermeable, slip-resistant outer layer, a bottom liquid impermeable substrate, and an intermediate cushion layer, the cushion layer including a foam core and liquid dampener attached to the outer layer and substrate. The substrate may comprise a liquid impermeable floor surface, a bathtub surface, a shower surface, a liquid impermeable backing, or a liquid impermeable backing bonded to an underlying surface.

The cushion layer comprises a resilient foam core containing a determined amount of liquid dampener. The foam core may be comprised of memory foam, foam rubber, rubber-latex foams, open-cell foams, closed-cell foams, polyurethane foam, visco-elastic polyurethane foam, polyethylene foam, or polyvinyl foam. The foam core may have an average thickness of ½ cm to 12 cm or ½ cm to about 5 cm.

The dampening liquid may comprise water, oil, or glycerine or other compatible non-toxic liquids, from 20% to 90% by weight of the cushion layer.

The durable, liquid impermeable, slip-resistant outer layer, may be comprised of a rubber-based material, vinyl, marine vinyl, faux leather vinyl or Whisper™ Vinyl.

Vertical panels comprising a durable, liquid impermeable, slip-resistant vertical outer layer, a vertical backing liquid impermeable substrate, and a vertical intermediate cushion layer may be attached.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other aspects, objects, features and advantages of the invention will become better understood with reference to the following description, appended claims, and accompanying drawings, where:

FIG. 1 conceptually shows layers of an exemplary cushioned surface with a durable, liquid impermeable, slip-resistant outer layer in accordance with principles of the invention; and

FIG. 2 is a cross sectional view of Section A-A of a bathtub (FIG. 3) equipped with an exemplary cushioned surface with a durable, liquid impermeable, slip-resistant outer layer in accordance with principles of the invention; and

FIG. 3 is a perspective view of a bathtub equipped with an exemplary cushioned surface with a durable, liquid impermeable, slip-resistant outer layer in accordance with principles of the invention.

Those skilled in the art will appreciate that the invention is not limited to the exemplary embodiments depicted in the figures or the shapes, relative sizes, proportions or materials shown in the figures.

DETAILED DESCRIPTION

With reference to the drawings, wherein like numerals represent like features, various views of an exemplary cushioned overlay with a durable, liquid impermeable, slip-resistant outer layer in accordance with principles of the invention.

Referring to FIG. 3, a perspective view of a bathtub 100 equipped with an exemplary cushioned surface with a durable, liquid impermeable, slip-resistant outer layer in accordance with principles of the invention are shown. The bathtub may be comprised of any conventional materials such as acrylic, fiberglass, porcelain-coated metal or other liquid impermeable materials. Although the exemplary tub is shown as roughly rectangular in shape, the invention is not limited to any particular shape or to use with a bathtub. Indeed, cushioned structures employing principles of the invention may include sections oriented horizontally, vertically and at angles. The sections may be substantially planar or curved. Thus, for example, in the case of a bathtub, panels comprising a durable, liquid impermeable, slip-resistant vertical outer layer, a vertical backing liquid impermeable substrate, and a vertical intermediate cushion layer may be attached to a horizontal structure.

Referring now to FIGS. 1 and 2, layers of an exemplary cushioned surface with a durable, liquid impermeable, slip-resistant outer layer in accordance with principles of the invention are conceptually shown. The layers include a bottom substrate 205, an intermediate cushion layer 210 and an outer layer 215.

The substrate 205 is a base material that is impermeable to liquid. The substrate 205 may comprise an underlying surface, such as an impermeable hard surface of a floor, bathtub or shower. Alternatively, the substrate 205 may comprise an impermeable backing material laid upon and bonded to a surface to be covered. Such backing materials may include vinyl, rubber, polyethylene and other polymeric and/or plastics adapted to provide a durable liquid impermeable base surface. An impermeable backing material would be utilized to provide a barrier that prevents seepage of liquids into an underlying surface. Such underlying surfaces may include flooring, furniture, mats, footwear inserts and the like. However, those skilled in the art will appreciate that the principles of the invention may be applied to any device or structure that may benefit from a cushioned surface or overlay.

The cushion layer 210 comprises a resilient core that provides cushioning and support. The cushion layer 210 may be of substantially constant thickness over a given substrate 205. Thus, the cushion layer 210 serves to reduce injury to a person who might fall on or against a cushioned surface (e.g., wall, floor, stair or bathtub), by cushioning the impact resulting from such a fall. Likewise, the cushion layer 210 serves to enhance comfort by providing a resilient base upon which a person may lean, stand or rest.

The cushion layer 210 may be composed of a variety of natural and synthetic cushioning materials. Non limiting examples of suitable materials for constructing the cushion layer 210 include foam materials, for example, memory foam, foam rubber, rubber-latex foams, open-cell or closed-cell foams, polyurethane, polyethylene, and polyvinyl foams. Resiliency of the foam material is preferred.

In a particular preferred embodiment, the cushion layer 210 is comprised of a memory foam (e.g., visco-elastic polyurethane foam) which readily adapts to the shape of a load and returns to its original shape when uncompressed. A memory foam's ability to distribute pressure across an entire surface of a load, helps ease pressure. By way of illustration and not limitation, a memory foam such as Omalon® foam by Carpenter Co. of Richmond, VA.

Advantageously, memory foams may be formulated and engineered to provide desired properties for a given application. For example, depending upon the foam formulation used and the overall density of the foam, it can be configured to be firmer in cooler temperatures and softer in warmer environments. Additionally, higher density memory foam will react with body heat and allow it to mould itself to the shape of a warm body within a few minutes. In contrast, a lower density memory foam is more sensitive to pressure and will mould more quickly to the shape of a body.

The cushion layer 210 may have an average thickness of about ½ cm to about 12 cm, preferably from about ½ cm to about 8 cm, and more preferably from about ½ cm to about 5 cm. In a preferred embodiment, the thickness of the cushion layer 210 is substantially uniform. However, the invention is not limited to any specific thickness, range of thicknesses, or uniformity or non-uniformity of thickness.

In a preferred implementation, the cushion layer 210 also contains a liquid referred to herein as a dampening liquid. The liquid may be water, oil, glycerin, or other liquid substances that are compatible with memory foam, and are preferably fire resistant and non-toxic. The liquid should also be stable and not decompose, become rancid or otherwise spoil. The liquid provides substantially enhanced thermal, cushioning and visco-elastic properties including hysteresis. Energy from a load quickly applied to a saturated foam cushion layer 210 is absorbed partially by liquid forced through cells or other openings within the foam, creating a dampening effect. The liquid is incompressible, thereby providing a barrier to even extreme loads. When a load is relieved, a saturated cushion layer 210 returns to its original undeformed state more slowly than otherwise. The liquid also improves heat transfer of the structure.

The amount and type of liquid may vary within the scope of the invention depending upon the desired properties and the volume and material comprising the cushion layer 210. In a preferred embodiment, a cushion layer 210 comprised of contains approximately 20% to 90% by weight of dampening liquid. In a particular preferred embodiment, the cushion layer 210 contains approximately 50% to 75% by weight of dampening liquid.

A durable, liquid impermeable, anti-slip cover layer 215 overlies the cushion layer 210, thereby encapsulating the cushion layer 210 between the substrate 205 and the liquid impermeable cover layer 215. In a preferred embodiment vinyl, such as marine vinyl, is utilized. In a particular preferred embodiment, premium, soft, “faux leather” vinyl is utilized. By way of example and not limitation, Whisper™ Vinyl by Spradling International, Inc., may be utilized. Such vinyl is soft, supple and manufactured in wide range of patterns, colors and textures. Such vinyl also features a slip resistant surface, favorable antimicrobial characteristics, mildew resistance, easy cleanability, fire retardance, durability, abrasion and stain resistance, color consistency, and liquid impermeability. Such vinyl is durable enough to resist tears, take extreme punishment and generally outperform the abrasion resistance and durability of many conventional surface materials. Such vinyl will not absorb liquids, and is not adversely affected by typical cleaners and other common household chemicals.

All of the embodiments of the present invention described or discussed above may be constructed by laminating and joining together various layers and sections of material which together form a composite material and structure of the present invention. The techniques and materials used for the laminating and adjoining will be evident to one of ordinary skill in that art. Various bonding agents and adhesives may be utilized. One would recognize, for instance, that the adhesives or bonding agents used to unite adjacent layers of the composite structure should be capable of forming a permanent, liquid impermeable, resilient bond, and should not be injurious or corrosive to the bonded layers of the composite material.

The laminate structure of the present invention provides a combination of properties which makes it especially useful as construction or safety material. The particular combinations described hereinabove provide a cushioned surface which is wear and tear resistant, durable and washable. The material also exhibits fire resistance, which makes it even more preferable for use in working and living spaces. The materials of the present invention combine these advantages with the feature that when desired the cover layer 215 can be provided with various designs (e.g., colors, patterns, artwork, logos, slogans, etc.). Thus, a cushion structure of the present invention combines aesthetic adaptability with physical properties which make the present invention an economically valuable product.

While an exemplary embodiment of the invention has been described, it should be apparent that modifications and variations thereto are possible, all of which fall within the true spirit and scope of the invention. With respect to the above description then, it is to be realized that the optimum relationships for the components of the invention and steps of the process, including variations in form, function and manner of operation, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. The above description and drawings are illustrative of modifications that can be made without departing from the present invention, the scope of which is to be limited only by the following claims. Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents are intended to fall within the scope of the invention as claimed. 

1. A cushioned structure comprising a durable, liquid impermeable, slip-resistant outer layer, a bottom liquid impermeable substrate, and an intermediate cushion layer, said cushion layer including a foam core and liquid dampener.
 2. A cushioned structure according to claim 1, wherein the substrate comprises a liquid impermeable floor surface.
 3. A cushioned structure according to claim 1, wherein the substrate comprises a structure from the group consisting bathtub surface and shower surface.
 4. A cushioned structure according to claim 1, wherein the substrate comprises a liquid impermeable backing.
 5. A cushioned structure according to claim 1, wherein the substrate comprises a liquid impermeable backing bonded to an underlying surface.
 6. A cushioned structure according to claim 1, wherein the cushion layer comprises a resilient foam core containing a determined amount of liquid dampener.
 7. A cushioned structure according to claim 6, wherein the foam core comprises a resilient foam core from the group consisting of memory foam, foam rubber, rubber-latex foams, open-cell foams, closed-cell foams, polyurethane foam, polyethylene foam, visco-elastic polyurethane foam, and polyvinyl foam.
 8. A cushioned structure according to claim 6, wherein the durable, liquid impermeable, slip-resistant outer layer, the bottom liquid impermeable substrate, and the intermediate cushion layer, are oriented horizontally, and said cushioned structure further comprises at least one attached vertical panel comprising a durable, liquid impermeable, slip-resistant vertical outer layer, a vertical backing liquid impermeable substrate, and a vertical intermediate cushion layer.
 9. A cushioned structure according to claim 6, wherein the foam core has an average thickness of ½ cm to 12 cm.
 10. A cushioned structure according to claim 1, wherein the dampening liquid comprises a compound from the group consisting of water, oil, and glycerin.
 11. A cushioned structure according to claim 1, wherein the dampening liquid comprises a liquid substance that is compatible with the cushion layer, substrate and outer layer.
 12. A cushioned structure according to claim 13, wherein the liquid substance is fire resistant and non-toxic.
 13. A cushioned structure according to claim 1, wherein the dampening liquid comprises twenty percent (20%) to ninety percent (90%) by weight of the cushion layer.
 14. A cushioned structure according to claim 1, wherein the cushion layer is saturated with dampening liquid.
 15. A cushioned structure according to claim 1, wherein the durable, liquid impermeable, slip-resistant outer layer, comprises vinyl.
 16. A cushioned structure according to claim 1, wherein the durable, liquid impermeable, slip-resistant outer layer, comprises marine vinyl.
 17. A cushioned structure according to claim 1, wherein the durable, liquid impermeable, slip-resistant outer layer, comprises faux leather vinyl.
 18. A cushioned structure according to claim 1, wherein the durable, liquid impermeable, slip-resistant outer layer, comprises Whisper™ Vinyl.
 19. A cushioned structure according to claim 1, wherein the durable, liquid impermeable, slip-resistant outer layer, comprises a rubber-based material.
 20. A cushioned structure comprising a durable, liquid impermeable, slip-resistant outer layer, a bottom liquid impermeable substrate, and an intermediate cushion layer, said cushion layer including a foam core and liquid dampener, wherein the dampening liquid comprises a liquid substance that is compatible with the cushion layer, substrate and outer layer, and the dampening liquid comprises twenty percent (20%) to ninety percent (90%) by weight of the cushion layer. 